Motor control system



July 2-1, 1953 R; B. TAYLOR MOTOR CONTROL SYSTEM Filed May 15, 1951 FORWARD F 6a R b 8 REVERSE Inventor- Robert B. Taylor,

His Attorney.

Patented July 21, 1953 2,646,540 Moron CONTROL SYSTEM Robert B.- Taylor, Schenectady, N. Y., assignor to General Electric Company, a corporation of New York Application May 15, 1951, Serial No. 226,471

7 Claims.

This invention relates to control systems and more particularly to systems for controlling the starting, acceleration and reversal of electric motors, and it has for an object the provision of a simple, reliable, improved and inexpensive control system of this character.

More specifically, the invention relates to control systems and direct current electric motors.

in which the motor is subject to reversals by plugging operation. A motor is plugged when the armature is rotating in one direction and a voltage is applied which tends to cause the armature to rotate in the opposite direction. A direct current motor may be plugged by reversing the voltage applied either to the field or to the arma ture.

7 During the usual motoring operation the counter-voltage of the motor opposes the line voltage and limits motor current to a relatively low value. When the motor is plugged the polarity of the counter-voltage is reversed and adds to the line voltage. If the motor is plugged when operating at full speed the resulting voltage, i. e. the sum of the line voltage and the counter-voltage would be approximately double line voltage. Chis would cause a current to flow in the armature circuit equal to many times the full load current unless restricted by some current limiting means; Accordingly, a further obj ect of this invention is the provision of means for limiting the current during plugging to a safe value.

In accelerating a motor from rest a plurality of accelerating contactors are provided for successively short-circuiting portions of a current limiting resistor in the armature circuit and a control device such as a time delay relay is utilized to interpose a predetermined interval of time between the sequential operations of the accelerating contactors.

A further and more specific object of the invention is the provision of a motor control system in which the number of parts required for accelerating and reversing the motor by plugging is reduced toa minimum.

In carrying the invention into effect in one form thereof, an electromagnetic relay is provided for interposing a predetermined interval of time between the sequential closings of the accelerating contactors. During reversal by plugging this timing relay serves to delay the beginning of the short-circuiting operations of the accelerating contactors to effect acceleration in the reverse direction until the additive polarity counter-voltage is reduced to a predetermined low value at which the short-circuiting of the current limiting resistor may be initiated without risk of damage to the motor.

For a better and more complete understanding of the invention, reference should now be had to the following specification and to the accompanying drawing of which the single figure is a simple diagrammatic sketch of an embodiment of the invention.

Referring now to the drawing, the invention is illustrated as embodied in a motor control system for an industrial battery operated truck in which the driving motor I is supplied from a conventional industrial type battery 2 the terminals of which are connected to energize the supply conductors 3 and 4 to which the'motor is arranged to be connected through a current limiting accelerating resistor 5. Although the motor I may be of any suitable type, it is preferably a series wound motor having an armature member la and a series field winding that is divided into two portions lb and lo.

A pair of electromagnetically operated reversing contactors Sand 1 which are under the control of a manually operated directional switch 8 serve to connect the motor to the supply conductors 3 and 4 for rotation in either direction.

A pair of electromagnetically operated accelerating contactors 9 and ID are provided for successively short-circuiting the portions 5a and 5b of the accelerating resistor respectively. A third electromagnetically operated accelerating contactor H is provided with normally closed contacts I la which serve to short-circuit the portion lb of the series field winding of the motor through a resistor I3 to provide the final step of acceleration by field weakening.

Control relay I4 serves to interpose a predetermined interval of time between the closings of the accelerating contactors 9 and I0, during acceleration from rest and it also serves during reversal of the motor by plugging to prevent the operation of the accelerating contactors to shortcircuit the current limiting resistance until the counter-voltage of the motor is reduced to a predetermined low value. The time delay in the operation of the control relay l4 may be affected by any suitable time delay means but is preferably affected by means of a discharge resistor I5 which is connected across the terminals of the operating coil [4a. When the coil Ma discharges through the resistor l 5, the reduced rate of decay of the current produces a correspondingly reduced rate of decay of the flux of the magnetic circuit which maintains the relay in its picked-up position until the current has decayed to a predetermined low value.

The sequential operation of the accelerating contactors is under the control of a multi-position master switch l5 which as illustrated in the drawing has an off position and three speed positions. For truck service the master switch is preferably a foot operated device.

With the foregoing understanding of the elements and their organization in the system, the i operation will readily be understood from the following detailed description. With the directional switch 8 and the master switch IS in their off positions in which they are illustrated, the relays and contactors described in the foregoing are in the normal deenergized position in which they are illustrated in the drawing. To place the control in condition for operation, the key switch i7 is closed to energize the supply conductor 4.

If it is desired to cause the motor to rotate in the forward direction, the directional switch 8 is moved to its upper closed position in which an energizing circuit is completed for the operating coil of the forward directional contactor 6. This circuit is traced from the positive supply conductor 3 through the fingers [3a and the bridging member (6b of the master switch contacts of the directional switch 8, operating coil Ba of the forward directional contactor to the negative supply conductor 4. In response to energization the forward directional contactor picks-up and opens its normally closed contacts 8b and closes its normally open contacts 60 and 6d. Contacts 6c in closing connect the armature id of the motor across supply conductors 3 and 4 with the full amount of the accelerating resistor 55 in circuit. An energizing circuit is also completed for the operating coil llb of accelerating contactor l I. This circuit is traced from the positive supply conductor 3 through contacts 5c of the forward contactor, normally closed contacts I Ea of the contactor ll, portion of the motor series field winding, normally closed contacts lb of the reverse contactor, conductor l8, fingers 280 of the master switch (connected together by strap 16d) operating coil Nb of the contactor H to the negative supply conductor 4. In response, contactor Ii picks-up and opens its normally closed contacts I la to insert the section lb of the series field winding in circuit with the section lc. As a result of the excitation of both sections lb and lo of the series field winding, the acceleration of the motor is initiated with full field so that the motor developes its maximum starting torque. Since the motor has full field strength and the full amount of accelerating resistor is in circuit with the motor, it accelerates from rest to a low speed.

Simultaneously, with the closing of the for ward contactor an energizing circuit is completed for the operating coil Ma of the control relay which is traced from the positive supply conductor 3 through main contacts 60 of the forward contactor, the resistor 53 and series field winding lb, 10, normally closed contacts 1'?) of the reverse contactor, contacts 8d of the forward contactor (closed in response to picking-up of the forward contactor), operating coil Eda, normally closed contacts 9b of the accelerating contactor, right hand portion of accelerating resistor a to the negative supply conductor :3. It will be noted that the coil of the relay i4 is connected from the left hand armature terminal of motor I to an intermediate point on the accelerating resistor. Thus, it is responsive to the motor voltage plus the voltage drop across the portion of the accelerating resistor between the right hand armature terminal and the intermediate point 50. Responsively to energization relay i i picks-up and opens its normally closed contacts Mb and closes its normally open contacts Mic. The opening of contacts 14b interrupts the energizing circuit for the operating coil 10a of the accelerating contactor III. The result of this interruption of the energizing circuit of contactor it is to prevent its being picked-up by operation of the master switch it until the control relay I4 is subsequently deenergized and dropped out.

Usually, after closing the manually operated directional switch 8, the operator operates the master switch from the off position through the first and second speed positions to the third speed position in a single movement and as rapidly as it is possible for him to do so. As the master switch leaves the off position the bridging member itb is moved out of engagement with the fingers Eta thereby interrupting the energizing circuit previously traced for t.e forward contaster. However, the forward contactor remains picked-up owing to a by-pass circuit through a resistor 8a which reduces the current through the coil 6a to a value insufficient to pick-up the contactor, but suflicient to hold it in once it has been picked-up. Contacts I40 in the closed position completes an energizing circuit for the operating coil 3a of the accelerating contactor 9. This circuit is traced from the positive supply conductor through the fingers (6c of the master switch bridged by segments lSf and strap 569, operating coil 9a and contacts I40 to the negative supply conductor 4. Contactor 9 picksup in response to energization and closes its normally open contacts to and 9d and opens its normally closed contacts Sb. Contacts in closing short-circuit the section 5a of the accelerating resistor thereby causing the motor to accelerate to a higher speed. Contacts M in closing complete a sealing-in circuit for contactor 9 independent of the contacts [40 of the control relay so that contactor 9 will remain picked-up after the control relay is subsequently dropped out. The opening of contacts 9b interrupts the energizing circuit for the operating coil Ma. Following the disconnection of the coil Ma from the source the coil discharges into the discharge resistor E5. This discharge current decays at an exponential rate and after an interval of time that is determined by inductance of the coil Ma and the resistance of resistor IS the magneto motive force of he magnetic circuit of relay M decays to such a low value that the relay drops out and closes its normally closed contacts 14b and opens its normally open contacts I40. As previously pointed out, the opening of contacts I40 does not drop out the contactor 9 which is sealed in through its interlock contacts 9d. However, the closing of contacts 14b completes an energizing circuit for the operating coil lOa of the accelerating contactor i=3. This circuit is traced from the positive supply conductor 3 through fingers 5th and cooperating segments lfii of the master switch, operating coil ma normally closed contacts Nib, and interlock contacts 9d to the negative supply conductor 4. In response to energization, accelerating contactor l0 picks-up and closes its normally open main contacts lUb to short-circuit the final section 5b of the accelerating resistor, thereby to accelerate the motor 7 to an intermediate speed. It is to be noted that thecontrol relay M has performed one of. its functions, i. e. the interpositionv of a time delay between the closing of the accelerating contactor. 9 and the accelerating contactor [0.

When the master switch passed from the second position tothe third position, it interrupted the energizing circuit for the operating coil of accelerating contactor !.l which'was previously traced through fingers lfic and segments Hid. However, the coil I lb remains energized by means of a by-pass circuit through normally closed contacts illc of the accelerating contactor I0 until the latter is picked-up. When contactor l0 picks-- up to short-circuit the-final portion of the accelerating resistor, contacts lllc open to interrupt'the by-pass circuit and drop out contactor l I. In the dropped out position of contactor H, normally closed contactors Ha short-circuit the section lb of the motor series field .winding thereby to weaken the field and to accelerate the motor to full speed.

' If while the motor is operating at full speed in the forward direction it is desired to operate the motor at full speed in the reverse direction the operator must return the master switch It to the off position and move the manually operated directional switch from the forward position to the reverse position. Reversal of the motor cannot be accomplished simply by movement of the directional switch to the reverse position without moving the master switch to its off po sition because with the master switch in a running position, an energizing circuit for the'opcrating coil of the reverse directional contactor can be completed only through the resistor 8a .2

which limits the current in the circuit to a value that is insuiiicient to pick-up the contactor. However, with the master switch in the off position the resistor 8a is short-circuited by the bridging member 16b thereby permitting sufiicient current to flow in the energizing circuit to pick-up the contactor. g

The mostrapid reversal of the motor is effected by manipulating the directional switch 8 and the master switch it so that thev directional switch closes its reverse contact and the master switch simultaneously reaches the off position, and then returning the master switch as rapidly as possible toits third or full speed running position.

As the master switch is returned through'the running positions to its otlposition, the contactors 8 and Ill are dropped-out and both sections 5a and 5b of the accelerating resistorare rein-- serted in the armaturecircuit with the result illustrated in the drawing. The movement of the through the series field winding with the result.

that the polarity of the counter-voltage of the motor is reversed and adds to the line. voltage. In the picked-up position of the reverse directional contactor the energizing circuit for the contactor H is reestablished.

The dropping out The circuit. is

traced from the positive supply conductor 3, through. contacts, lc of the reverse contactor, section lc of the motor field windingv and. thence through the contacts Ila and alsothrough section lb of the field winding and resistor [3 in parallel with contacts Ila through normally closed contacts 6?) of the forward contactor, contacts Hlc of the accelerating contactor H1, oper-- ating coil H'b to the negative supply conductor: Contactor ll picks-up and removes the shortcircuit from the section lb of the series field winding with theresult that full field strength of the motor is established with the motor still op.- erating at substantially full speed in the forward direction. At, this point the counter-voltage is substantially equalto the line voltage and since it adds. to the line voltage, substantially double line voltage, is applied across the current limiting. resistor 5. If it were. possible for the control to short-circuit the resistor 5 at this instant, the current in the armature circuit would rise to many times the maximum permissible value with the result of damage to the insulation.

This undesirable condition is, however, prevented by the control relay l4. As previously pointed out, theoperating coil of this control relay is connected from the left hand armature terminal to an intermeidate point 50 on the accelerating resistor in response to closing of either of the directional contactors. Since: the voltage drop acrossthe resistor. opposes thev additive: line voltage and countervoltage, the voltage of the point. 50 which. is approximately the mid-point of resistor 5 is substantially equal to, the. voltage of the left hand. armature terminal. The. result. is that substantially zero voltage is appliedacross the terminals of the coil Ma of the control relay. Consequently, a very small current flows in its coil circuit which is insufficient to pick-up the relayand as long as the relay remains dropped out the accelerating contactors 9 and I!) cannot be energized and picked-up.

The large current which flows in the armature circuit as the result of the application of double line voltage across the accelerating resistor produces apowerful braking torque which rapidly brakes the motor to rest. As the speed and difference appears between the left hand armature' terminal and interemdiate point 50 on the resistor. At a predetermined low speed of the motor the counter-voltage is reduced to such a low valuethat substantially only line voltage is applied across the resistor. Under this condition, the short-circuiting of theresistor to accelerate the-motor in the reverse direction may be safely initiated. At this predetermined low speed the difierence voltagebetween the left hand armature terminal and the'point 5c attains a value which causes sufilcie'nt current to flow in the operating coil I ia to pick-up the control relay and initiatethe closing of the accelerating contactors 9 and I1]. From this point the acceleration proceeds in the manner already described in relation to the acceleration in the forward direction.

Thus, it will benoted that in addition. to interposing a time delay between the successive closings of the accelerating contactors 9' and it during acceleration of the motor in either direction, the control relay performs the additional function during reversal of preventing the clos-- ing of. the accelerating contactors. until the counter-voltage of. the motor has decreased to predeterminedlow value at which it is safe to begin short-circuiting the accelerating resistor.

Although in accordance with the provisions of the patent statutes this invention is described as embodied in concrete form and the principle thereof has been explained together with the best mode in which it is now contemplated applying that principle, it will be understood that the elements shown and described are merely illustrative and that the invention is not limited thereto since alterations and modifications will readily suggest themselves to persons skilled in the art without departing from the true spirit of this invention or from the scope of the annexed claims.

What I claim as new and desire to secure by Letters Patent of the United States is:

1. A control system comprising in combination a pair of supply conductors, a direct current electric motor, a directional switch having forward and reverse operating positions, forward and reverse directional contactors selectively operable in response to selective operation of said directional switch to said operating positions to connect said motor to said supply conductors for rotation in a selected direction, a current limiting resistor connected in the armature circuit, first and second accelerating contactors for sequentially rendering portions of said resistor inefiective, a relay responsive to the voltage drop across a portion of said armature circuit during starting of said motor for efiecting operation of said first accelerating contactor and subsequent operation of said second accelerating contactor and responsive to the reverse polarity counter-voltage of said motor for delaying the operation of said first accelerating contactor until the speed of said motor is decreased tc a predetermined low value in response to operation of said directional switch from one of said operating positions to the other to effect reversal of said motor and a time delay device on said relay responsive to operation of said first accelerating contactor for interposing a predetermined time interval between the sequential operations of said first and second contactors.

2. A control system comprising in combination a pair of supply conductors, a direct current electric motor, a directional switch having forward and reverse operating positions, forward and reverse directional contactors selectively operable in raponse to selective operation of said directional switch to said operating positions to connect said motor to said supply conductors for rotation in a selected direction, a current limiting resistor connected in the armature circuit, first and second accelerating contactors for sequentially rendering portions of said resistor ineffective, a relay having an armature operated to a first position in response to the voltage drop across a portion of said armature circuit for effecting operation of said first accelerating contactor and operable to a second position in response to said operation of said first accelerating contactor to effect operation of said second accelerating contactor, and operated to said first position in response to the combined reverse polarity counter-voltage of said motor and voltage drop across said resistor at a predetermined low speed of said motor produced during deceleration in response to operation of said directional switch from one of said operating positions to the other to reverse said motor, and a time delay device on said relay responsive to operation of said first accelerating contactor for interposing a predetermined time interval between the operations of said relay armature to said first and second positions.

3. A control system comprising in combination a pair of supply conductors, a direct current electric motor, a directional switch having forward and reverse operating positions, forward and reverse directional contactors selectively operable in response to selective operation of said directional switch to said operating positions to connect said motor to said supply conductors for rotation in a selected direction, a current limiting resistor connected in the armature circuit of said motor, first and second accelerating contactors for sequentially rendering portions of said resistor ineffective and a relay having an operating coil energized in response to the voltage drop across a portion of said armature circuit for effecting operation of said first accelerating contactor and responsive to operation of said first accelerating contactor for effecting operation of said second accelerating contactor and responsive to the reverse polarity counter-voltage of said motor to delay the closing of said first accelerating contactor until the speed of said motor is decreased to a predetermined low value in response to operation of said directional switch from one of said operating positions to the other to reverse said motor and responsive to the voltage across said portion of said circuit at said low speed for effecting operation of said first accelerating contactor.

4. A control system comprising in combination a pair of supply conductors, a direct current electric motor, a directional switch having forward and reverse operating positions, forward and. re verse directional contactors selectively operable in response to selective operation of said directional switch to said operating positions to connect said motor to said supply conductors for rotation in a selected direction, a current limiting resistor connected in the armature circuit of said motor, first and second accelerating contactors, a multi-position master switch for providing sequential operation of said accelerating contactors for sequentially rendering portions of said resistor ineffective, and a relay having an operating coil energized by the voltage drop cross said armature and a portion of said resistor for interposing a predetermined time delay between the operations of said first and second accelerating contactors and responsive to the reverse polarity counter-voltage of said motor to delay the closing of said first accelerating contactor until the counter-voltage of said motor is decreased to a predetermined low value in response to operation of said directional switch from one of said operating positions to the other to reverse said motor.

5. A control system comprising in combination a pair of supply conductors, a direct current electric motor, a directional switch having forward and reverse operating positions, forward and reverse directional contactors selectively operable in response to selective operation of said directional switch to said operating positions to connect said motor to said supply conductors for rotation in a selected direction, a current limiting resistor connected in the armature circuit of said motor, first and second accelerating contactors for sequentially rendering portions of said resistor ineffective and a relay having an operating coil connected to be energized by the voltage drop across the armature of said motor and a first portion of said resistor and having an armature picked-up in response to energization to effect operation of said first accelerating contactor to render a portion of said resistor inefiective and dropped out in response to deenergization to effect operation of said second accelerating contactor to render a second portion of said resistor ineffective, an auxiliary contact on said first accelerating contactor opened in response to said operation of said first accelerating contactor for interrupting the energizing circuit of said relay, a discharge resistor connected across said relay operating coil for interposing a predetermined interval of time between said operation of said first accelerating contactor and the drop out of said relay, said relay being responsive to the combined reverse polarity counter-voltage of said motor and the voltage drop across said first portion of said resistor for delaying the pick-up of said relay until the speed of said motor is decreased to a predetermined low value in response to operation of said directional switch from one of said operating positions to the other to reverse said motor.

6. A control system comprising in combination a pair of direct current supply conductors, an electric motor, a pair of directional contactors for connecting said motor to said source for rotation in either direction, a current limiting resistor connected in the armature circuit of said motor, first and second accelerating contactors for rendering corresponding sections of said resistor ineffective, a directional switch for producing selective operation of said directional contactors to connect said motor to said supply conductors for rotation in a selected direction, a master switch for controlling the operation of said first accelerating contactor and the subsequent operation of said second accelerating contactor to render said portions of said resistor ineffective, and a relay responsive to the voltage drop across the armature of said motor and a selected portion of said resistor for interposing a time delay between the operations of said first and second accelerating contactors during acceleration, and

responsive to the Voltage drop across said selected a iii 7. A control system comprising in combination a pair of supply conductors, a direct current motor, a directional switch, a forward directional contactor operable in response to operation of said directional switch to a first position to connect said motor to said source for rotation the forward direction, a current limiting resistor in circuit with said armature, a relay having an operating coil connected across the armature of said motor and a portion of said resistor for energization in response to operation of said contactor and having a first contact operated in response to energization, a first accelerating contactor closed in response to operation of said contact for short-circuiting a portion of said r sistor and for interrupting the energizing circuit of said relay, a discharge resistor connected across said relay coil for delaying the drop out of said relay for a predetermined interval of a second contact on said relay closed in response to deenergization of said relay, a second accelcrating contactor closed in response to closing of said second contact to short-circuit a second portion of said resistor, a master switch for opening said accelerating contactors to reinsert the short-circuited portions of said resistor in said armature circuit, said forward directional contactor being opened in response to opening of said directional switch to interrupt the con nections of said motor to said supply conductors and to interrupt the energizing circuit of said relay coil, and a reverse directional contactor responsive to operation of said directional switch to a second position to connect said motor to said supply conductors with the polarity of the counter-voltage reversed with respect to the voltage of said supply conductors for rotation in the reverse direction and for connecting said relay coil across a portion of said resistor and said armature, said reverse polarity combining with said supply voltage to maintain said relay deenergized until the speed of said motor is reduced to a predetermined low value.

ROBERT B. TAYLOR.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date 1,802,765 James Apr. 28, 1931 1,847,081 Cook Mar. 1, 1932 

